Vacuum Brake Booster: Service and Repair

Power Vacuum Brake Booster Replacement (With RPO LAT) (2.4L)
Caution: Refer to Brake Fluid Irritant Caution .

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .



Removal Procedure


Notice: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM.

1. Turn the ignition to the OFF position.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
3. Remove the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .




4. Remove the 3 nuts that attach the electronic brake control module (EBCM)/brake pressure modulator valve (BPMV) bracket to the left front wheelhouse.
5. Disconnect the power brake booster vacuum sensor electrical connector, if equipped.
6. Disconnect the brake master cylinder pressure sensor electrical connector, if equipped.
7. Lower the vehicle.




8. Disconnect the electrical connector from the EBCM.
9. Without disconnecting the hoses, position aside the radiator surge tank. Refer to Radiator Surge Tank Replacement (Service and Repair) .




10. Deplete the vacuum from the vacuum brake booster by removing the vacuum check valve (1) from the vacuum brake booster grommet (4). Do not disconnect the vacuum check valve from the vacuum brake hose (3).

Important: Cap the brake pipe fittings to prevent brake fluid loss and contamination.






11. Remove the 4 brake pipes (2) from the BPMV.




12. Remove the master cylinder nuts from the vacuum brake booster.




13. Remove the EBCM/BPMV bracket assembly with the brake master cylinder.
14. Remove the left side instrument panel insulator panel. Refer to Instrument Panel Insulator Replacement - Left Side .
15. Remove the electrical connector from the brake apply sensor.




16. Remove the 2 brake pedal assembly to cowl mounting nuts.




17. Disconnect the brake pedal pushrod retaining clip (1) the wave washers (2) and the brake booster pushrod (3) from the brake pedal pin (4).
Tilt the vacuum brake booster slightly in order to work the booster pushrod off the brake pedal pin. Do not apply excessive side pressure on the pushrod.
18. Remove the booster from the vehicle.



Installation Procedure





1. Install the booster to the vehicle.
2. Tilt the vacuum brake booster slightly in order to work the booster pushrod onto the brake pedal pin. Do not apply excessive side pressure on the pushrod. Align the pushrod with the pedal and assemble.
3. Connect the brake pedal pushrod retaining clip (1) the wave washers (2) and the brake booster pushrod (3) to the brake pedal pin (4).





Notice: Refer to Fastener Notice .

4. Install the 2 brake pedal assembly to cowl mounting nuts.

Tighten the nuts to 15 N.m (11 lb ft).

5. Install the electrical connector to the brake apply sensor.
6. Install the left side instrument panel insulator panel. Refer to Instrument Panel Insulator Replacement - Left Side .




7. Install the EBCM/BPMV bracket assembly and the master cylinder to the vehicle.





Important: Ensure the gasket on the outside barrel of the master cylinder is positioned properly and is free of cuts and tears.


8. Install the master cylinder nuts to the vacuum brake booster.

Tighten the nuts to 25 N.m (18 lb ft).

9. Raise the vehicle.




10. Install the 3 nuts that attach the EBCM/BPMV bracket assembly to the left wheelhouse.

Tighten the nuts to 10 N.m (89 lb in).

11. Connect the power brake booster vacuum sensor electrical connector, if equipped.
12. Connect the brake master cylinder pressure sensor electrical connector, if equipped.
13. Install the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
14. Lower the vehicle.




15. Install the 4 brake pipes (2) to the BPMV.

Tighten the pipes to 20 N.m (15 lb ft).





16. Connect the electrical connector to the EBCM.




17. Connect the vacuum brake booster check valve (1) to the vacuum brake booster grommet (4).
18. Position the radiator surge tank to the bracket. Refer to Radiator Surge Tank Replacement (Service and Repair) .
19. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (Service and Repair)Hydraulic Brake System Bleeding (Pressure) (Service and Repair) .
20. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration .